Lean production planning and control in semi-process industries.pdf

Lean production planning and control in semi-process industries.pdf

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Norwegian University of Science and Technology Department of Production and Quality Engineering Lean production planning and control in semi-process industries Joaquim Fernàndez Clotet Erasmus + exchange program - Master Thesis Submission date: February 2015 Supervisor: Professor Erlend Alfnes Co-supervisor: Dr. Philipp Spenhoff
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I Preface Lean production planning and control in semi-process industries is the work developed as a master ’s thesis in production and quality engineering. It has been done in the NTNU from September 2014 until February 2015 as part of the ERASMUS + exchange program. This project was proposed by the supervisor Erlend Alfnes who gave me all the tools and resources necessaries to get into it. This is written to be understood for any industrial management engineer with notions of manufacturing industries. NTNU- IPK February 2015 Joaquim Fernandez Clotet
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II Abstract Process Industries have traditionally been lumped together on the basis of producing non- discrete products. However, some of these industries are hybrid of process sector as at some point of their production process the products are discretized and treated as discrete units. This hybrid manufacturing environments can be classified as another type of manufacturing industries, under the name of semi-process industries. The notion of the discretization point which reflects this hybridity was firstly introduced by Abdulmalek, Rajgopal, and Needy (2006) and later highlighted by Pool, Wijngaard, and Van der Zee (2011). Production planning and control environments are defined by the interaction of the customer demand, production process and product produced. Although they are not totally dependent one from each other, these three elements are closely related. This dependency was already reflected in the traditional product-process matrix from Hayes and Wheelwright (1984), but the matrix captured an overall dependency without analysing in a more granular way. This matrix has been expanded and gained detail with the research of current classification for production planning and control and process manufacturing environments. With this information, manufacturing environments for semi-process industries have been studied and characterised. Lately, manufacturing environments have been focusing their efforts on reaching levels of optimisation. Moreover, reducing waste on every one of their production steps and making their processes more flexible in order to accommodate wider demand variation and order fulfilment. Therefore, lean manufacturing methodologies have been implemented in manufacturing industries in order to reach these goals. Production planning and control tools (PPC tools) are between all these lean concepts a small portion which can have reliable profits. Applicability in discrete sectors has been widely demonstrated (Bokhorst & Slomp, 2010; Liker, 2004). On the other hand, applicability of lean methodologies on process sectors still remains behind due to the rigid properties of these sectors (i.e. inflexible equipment, long set-up and changeover times). Therefore, applying this manufacturing concepts and tools in
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  • Fall '15
  • The Land, Process Industries, Discrete industries, semi-process industries

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